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11

Maintenance and troubleshooting

11.1

Visual inspection

Inspect the product and cables for visible external damage and note the operating status display, where applic-
able. In the event of damage, notify your installation engineer. Repairs may only be carried out by authorised
electricians.

DANGER

Dangerous voltage due to two operating voltages

Severe injuries or death may occur if the cables and/or terminals/busbars in the device are touched. The dis-
charge time of the capacitors is up to 5 minutes.

1. Only appropriately qualified electricians authorised by the mains supply network operator are permitted to

open and maintain the device.

2. Before opening the device: Disconnect the AC and DC sides and wait at least 5 minutes.

NOTE

There are components in the housing of the device which may only be repaired by the customer service team.

1. Do not attempt to repair faults that are not described here (in the chapter on troubleshooting and fault

rectification). Contact our Customer Service department. Only perform the maintenance work that is de-
scribed here.

2. Log each maintenance activity in the "Service" menu item: “Service Log” (exception: “User” interface) [See

3. The device should be checked for proper operation by a qualified electrician at regular intervals and if you

experience problems, you should always contact the system manufacturer’s Service department.

11.2

Cleaning

11.2.1 Cleaning the housing

CAUTION

Risk of damage to the device during cleaning!

1. Do not use compressed air or high-pressure cleaners.

2. Use a vacuum cleaner or a soft brush to remove dust from the fan cover and from the top of the device on a regular

basis.

3. Remove dust from the ventilation inlets if necessary.

11.2.2 Cleaning the heat sink

WARNING

Risk of burns from hot surface.

Heat sinks become very hot when in operation.

1. Never touch the heat sinks after commissioning the device.

2. Allow the heat sinks at least 10 minutes to cool down before cleaning.

Manual

Maintenance and troubleshooting | 11

KACO blueplanet 100 TL3

Page 91

EN

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Содержание 1001950

Страница 1: ...man original KACO blueplanet 100 TL3 These instructions form part of the product and must be carefully read observed and stored in a place which is freely accessible at all times Authorised electricia...

Страница 2: ...ated as a unit for reading reasons Trademarks All brand and product names used in this document are trademarks or registered trademarks A lack of identi fication does not mean that a product or design...

Страница 3: ...erfaces 28 7 10 Sealing the connection area 31 8 Commissioning 32 8 1 Requirements 32 8 2 Network topologies 33 8 3 Start up options 34 9 Configuration and operation 39 9 1 Initial start up 39 9 2 Sig...

Страница 4: ...uages The German language version is the original version All other language versions are translations of the original version This document is valid for the following types of device from firmware ve...

Страница 5: ...r instructions Prerequisite for use 1 Carry out the next step 2 Additional action sequence Interim result of the action End result 1 4 Identification You will find the name plate with the following da...

Страница 6: ...d personnel with the follow ing qualifications Knowledge about how an inverter functions and operates Knowledge of the Modbus specifications Knowledge of the SunSpec Modbus specifications Training in...

Страница 7: ...ice Do not touch the electrical connections Remove all jewellery from wrists and fingers Ensure that the testing equipment is in safe operating condition Modifications to the surroundings of the devic...

Страница 8: ...the manufacturer Overvoltage on the DC connection of over 1 500 V Device modification Standalone mode 2 2 Protection features The following monitoring and protection functions are integrated in the d...

Страница 9: ...ion button USB port 4 Display indication 9 DC connection cable feed through 5 Upper cover 10 DC isolator switch 3 2 1 Mechancial Components DC isolator switch not present in S version The DC isolator...

Страница 10: ...erface is earmarked for communication with a string combiner box This can be controlled using the Modbus RTU protocol Data loggers that cannot be connected via Ethernet can be connected to the other R...

Страница 11: ...cable from the PV generator to the device is long the string combiner can also be installed in the vicinity of the PV generator An integrated DC isolator switch enables disconnection on the DC side Sw...

Страница 12: ...ge range continuous operation Rated current Max continuous current 3 x 152 A Contribution to peak short circuit current p 260 8 A Initial short circuit alternating current Ik first single period effec...

Страница 13: ...0 db A Housing material AL H x W x D 719 mm x 699 mm x 460 mm Weight 78 2 kg Grid connection directive Overview see homepage download area 4 3 Environmental data Environmental conditions Max installat...

Страница 14: ...e device We will be glad to help you if necessary 5 2 Transporting the device CAUTION Hazard due to impact risk of breakage to the device 1 Pack the device securely for transport 2 Transport the devic...

Страница 15: ...cation 5 Immediately remove dirt especially on vents 6 Failure to observe these warnings may lead to device damage which is not covered by the manufacturer warranty NOTE Access by maintenance personne...

Страница 16: ...of injury caused by excessive physical strain Lifting the device for transport relocation and assembly can result in injuries e g back injuries 1 Only lift the device using the openings provided 2 The...

Страница 17: ...ixing materials that are suitable for the mounting base The fastening materials supplied are only to be used for masonry and concrete 2 Only install the device in an upright hanging position 153 mm A...

Страница 18: ...climbing aid for the chosen installation height 3 Wear protective gloves and safety shoes when lifting and lowering the device NOTE Power reduction due to heat accumulation If the recommended minimum...

Страница 19: ...the electrical installation CAUTION Property damage as a result of condensation During pre assembly of the device moisture can penetrate into the interior via the dust protected threaded connections T...

Страница 20: ...evice has been installed on the mount Wipe any moisture off the frame of the housing cover using a cloth 1 Undo the 6 screws 2 and carefully remove the housing cover 1 T_25 2 Take care not to damage o...

Страница 21: ...240mm AL or CU Min cable cross section in accordance with local installation standards Cable diameter for cable fitting 16 28 mm Length of insulation to be stripped off Depending on the cable lug Cab...

Страница 22: ...ving the AC input plate 1 Housing base AC side 2 Screws for mounting 3 Input plate 4 Cable fitting 7 5 2 Make the grid connection 4 pole connection TN TT system Grid connection is prepared 1 Loosen nu...

Страница 23: ...table voltages can be measured there is a ground fault in the DC generator or its wiring The ratio between the measured voltages gives an indication as to the location of this fault 3 Rectify any faul...

Страница 24: ...switchbox or string combiner with the DC isolator switch 2 Only touch the PV generator cables on the insulation Do not touch the exposed ends of the cables 3 Avoid short circuits 4 Do not connect any...

Страница 25: ...surge in voltage 8 Guide the shrink tubing over the uninsulated crimping point and a maximum of 20 0 2 mm over the cable insulation and shrink fit using manual shrink fitting equipment 9 Secure the in...

Страница 26: ...ntermediate plug in frame onto AC surge protection socket NOTE Different AC surge protection modules are used The designation on the PCB must match the module code GTD MOV 1 Insert AC surge protection...

Страница 27: ...the output cable to the cable guide 8 Insert RS485 overvoltage protection module into the base socket 9 Ensure that the protective elements are properly secured Proceed with the installation of the p...

Страница 28: ...vice can be damaged beyond repair by static discharge 1 Observe the ESD protective measures 2 Earth yourself before touching a component by touching a grounded object All interfaces are located on the...

Страница 29: ...of the cable fit ting through the sealing insert NOTE Use a suitable category 7 network cable The maximum distance between two devices is 100 m 328 ft The Ethernet switch allows for the repeater func...

Страница 30: ...connected to all inverters and to the data monitor unit in the same way Wire A to wire A and wire B to wire B GND to GND 5 Tighten the cable fittings W_20 1 5 Nm NOTE When using the RS485 bus system a...

Страница 31: ...loosely tighten the fastening screws 2 Secure the housing cover 1 by tightening all 6 screws 2 in a diagonally oppos ite sequence T_25 5 Nm The device has been mounted and installed Put the device in...

Страница 32: ...voltage 1 Connect the grid voltage using the external circuit breakers 2 Connect the PV generator using the DC isolator switch 0 1 The device begins operation During initial start up Follow the instru...

Страница 33: ...ct in the segment switch via glass fibre cable Located directly after the Gateway VPN Router is the main network switch via which the segment control ler is connected in With the corresponding system...

Страница 34: ...lable in future development levels A device configuration that is available on the Plant Controller can be uploaded to the relevant devices via the subordinate Segment Controllers 8 3 1 Start up via W...

Страница 35: ...ication circuit board has 3 Ethernet ports that can be used 1 The 2 neighboring shielded Ethernet ports are marked LAN1 and LAN2 These ports have an internal switch and in their factory default state...

Страница 36: ...equired components A notebook that is logged into the external network Ethernet cable uncrossed patch cable The device can also be operated without an external Segment Controller or data logger In thi...

Страница 37: ...Segment Controller NOTE When multiple Segment Controllers are present keep in mind that the Segment Control lers must not be connected to one another via the network during start up 7 Once start up is...

Страница 38: ...n file Plant Controller Procedure 1 Connect the notebook to the Plant Controller via Ethernet or a WiFi compatible Client 2 Upload a pre prepared device configuration e g a device configuration that h...

Страница 39: ...Country configuration A language has been selected 1 Select Country and Grid type from the dropdown menu 2 Confirm the action field The Forward button jumps to the next installation step Fig 43 Menu i...

Страница 40: ...concerns over security write access can be deac tivated 1 Specify the Modbus port and determine Read write access 2 Confirm the action field The Forward button jumps to the next installation step Fig...

Страница 41: ...erating states The LEDs can display the following states LED illuminated LED flashing LED not illuminated Description LED Icon Operating status Start The green LED Operation lights up when AC and DC v...

Страница 42: ...s will take up to 5 min for firmware updates or up to 30 sec for parameter updates Process is initiated update The green LED Operation and the green LED Feed in flash simultaneously fast Note After 10...

Страница 43: ...ured values and yield data which are shown alternately at an interval of 7 seconds Fig 52 Desktop sequence 9 4 User interface NOTE Depending on the tolerances of the measuring elements the measured an...

Страница 44: ...e Current power Status history Activity indicators for communication interfaces Fig 53 Monitoring interface Area Description Basic layout 1st tab Displays the current reactive power factor Displays th...

Страница 45: ...uage Field of action Yield Monitor Configuration Info Collapse all Expand all Parameters Overview Parameters Grid Parameters Interfaces Power Control Power Limitation Internal External System Maintena...

Страница 46: ...parameter Once you have entered the password protection will be disabled for all protected grid parameters including the password protection setting for 15 minutes Protection is reactivated automatica...

Страница 47: ...ng data graphically F Select a week The web interface shows the selected data 4 1 2 3 4 Monthly view Displays the recorded operating data graphically F Select a month The web interface shows the selec...

Страница 48: ...directly connected to the device are entered in the segment controller Baud rate number of data acquisition units 9600 8n1 1 Specify transmission and detection intervals 2 Enter the number of data acq...

Страница 49: ...ynamic grid stabilization Fault Ride Through NOTE More detailed information at See sec tion 10 3 Page 83 4 1 2 3 4 Operation mode On Off F Select a control process On Activates dynamic grid support us...

Страница 50: ...o zero current mode The total current is regulated to virtually zero 4 1 2 3 4 Reactive current limita tion 0 100 Imax 100 Imax 1 F Set the reactive power limitation 4 1 2 3 4 Minimum support time 100...

Страница 51: ...factor 5000 5000 0 00 Hz s 1 Status 1 Define the proportionality factor 2 Confirm the action field 4 1 2 3 4 Ramp Rate Limitation NOTE Opportunity to limit power in the case of an increasing and decr...

Страница 52: ...ure 10 110 Unom 0 1 Max conn voltage after grid failure 90 125 Unom 0 1 F Specify switch on voltage range after grid error 4 1 2 3 4 Min conn frequency after grid failure 45 65 Hz 0 01 Max conn freque...

Страница 53: ...arameters frequency or voltage 4 1 2 3 4 Generic parameters NOTE Opportunity to activate standard protective shutdown 4 1 2 3 4 Trip with intentional delay Status 1 If necessary activate delayed trip...

Страница 54: ...evel 2 5 42 5 65 Hz 47 5 Hz 0 01 Trip underfrequency time level 2 5 0 1000000 ms 100 1 4 1 2 3 4 Trip overfrequency monitoring Status F Activate if necessary 4 1 2 3 4 Number of trip overfre quency le...

Страница 55: ...ge level 2 5 10 100 Unom 45 Unom 0 1 Trip undervoltage time level 2 5 0 120000 ms 1 4 1 2 3 4 Trip overvoltage monit oring Status F Activate if necessary 4 1 2 3 4 Number of trip over voltage levels 1...

Страница 56: ...que IPv4 address in the network 4 1 2 3 4 Subnet Mask F Assign a subnet mask 4 1 2 3 4 Default gateway F Enter IPv4 address of the gateway 4 1 2 3 4 DNS server settings via DHCP Status F Activate or d...

Страница 57: ...on the HMI board via DIP switch F Confirm the action field 4 1 2 3 4 Power Control Input screens for power regulation 4 1 2 3 4 Power Limitation NOTE The output power of the device can be set permane...

Страница 58: ...fallback value cos phi constant Q con stant or fallback power NOTE If the fallback time is set to 0s external settings for cos phi Q and P are not reset operation continues with the last received setp...

Страница 59: ...in the event of an abrupt change in the reactive power target value e g caused by a voltage jump 2 Activate optional password protection 3 Confirm the action field 4 1 2 3 4 Q constant NOTE Define th...

Страница 60: ...e selected grid type F Specify the number of nodes 4 1 2 3 4 Node 1 Node 10 0 100 Slim 0 50 100 Slim 1 F Power factor for 1st 10th node as a percentage of the maximum power NOTE For the 1st node the p...

Страница 61: ...to under excited mode 4 1 2 3 4 Settling time 1000 120000 ms 1000 ms 10 F Set the response speed of the control 4 1 2 3 4 Minimum cos phi Q1 Minimum cos phi Q4 0 1 0 0 001 F Enter the minimum cos fact...

Страница 62: ...or underfrequency 2 Determine control method for overfrequency 4 1 2 3 4 Gradient 0 200 Pref Hz 40 Pref Hz 1 F Set gradient of power limitation function with increasing frequency This percentage relat...

Страница 63: ...n increase Output gradient limitation de crease 1 65534 Slim min 65534 Slim min 1 F Specify the increasing and decreasing output gradient 4 1 2 3 4 P f settling time 200 2000 ms 200 ms 1 ms Password p...

Страница 64: ...characteristic curves can be configured inde pendently and one of them can be activated for regulation each time 4 1 2 3 4 Number of nodes 2 5 F Specify the number of nodes Power 0 0 100 0 Pref 100 Pr...

Страница 65: ...ed into the PV system 4 1 2 3 4 Password protection Status 1 Option to set password protection 2 Confirm the action field 4 1 2 3 4 SPD monitoring NOTE Opportunity to check the overvoltage protection...

Страница 66: ...Enter the meter reading in the input field 4 1 2 3 4 Operating hour counter 0 xxx hour NOTE Opportunity to transfer the operating hours of a re placement device 1 Enter the hours in the input field 2...

Страница 67: ...e with update 4 1 2 3 4 Check for Available software packages Network connection available 1 Checks for available device updates online using the existing net work connection 2 Start the firmware upda...

Страница 68: ...itoring the device You have connected the device to your network 1 When using a DHCP server Activate DHCP 2 For manual configuration DHCP off 3 Open the Settings Network menu 4 Assign a unique IP addr...

Страница 69: ...ase of error you must repeat the update process Update process successfully completed Device with multifunction buttons Ensure power supply 1 Insert USB stick into the USB socket of the device 2 Use m...

Страница 70: ...the Feed in LEDs are flashing slowly and in tandem 1 sec this indicates that a function has been completed successfully If the Fault LED is flashing slowly 1 sec this indicates that a function has not...

Страница 71: ...Signal Icon LED status Meaning Note No fault Manual Configuration and operation 9 KACO blueplanet 100 TL3 Page 71 EN...

Страница 72: ...our as described below 10 1 2 Reactive power functions The following functions for controlling the reactive power are implemented in the devices listed above cos constant Q constant cos p pn Q U 10 no...

Страница 73: ...e slower than the configured Tau 200 ms by way of a defined gradient or settling time this gradient or settling time must be im plemented in the system control Parameters Setting Refer ence Descriptio...

Страница 74: ...ort is provided by the reactive power as soon as the voltage actually deviates from the target voltage In this case a characteristic curve is specified which can be used to configure up to 10 nodes va...

Страница 75: ...5 534 Slim min 1 Maximum change in the reactive power Slim min in the event of a change to over excited mode NOTE The gradient is overlaid with the settling time Settling time 1 000 120 000 ms 1 000 m...

Страница 76: ...cess is delayed by the set dead time Once the dead time has expired the control circuit is no longer subject to a delay and the set transient time determines the transient behaviour Rise Outg grad Fal...

Страница 77: ...necessary this can be used to reduce the feed of the inverter If it is not possible to compensate adequately for voltage excesses in the upstream distribution network by in take on reactive power it...

Страница 78: ...ue storage may be below the specified limit value Depending on the inverter series the settling time and gradient limitation may be adjustable Parameters Setting Refer ence Description Power Limitatio...

Страница 79: ...is and a deactivation threshold below the activation threshold 10 2 3 1 Parameters for P U Country spec Set tings Men u level Display Setting Action in this menu meaning 4 1 2 3 4 Operation mode Off O...

Страница 80: ...sing gradient 4 1 2 3 4 Active curve 1 5 F Select the active curve NOTE Up to 5 characteristic curves can be configured inde pendently and one of them can be activated for regulation each time Number...

Страница 81: ...require adjustment of the active power P f in the event of underfre quency Due to the fact that PV systems are typically run at the maximum power point there are no power re serves for increasing the...

Страница 82: ...ion is deactivated if the frequency returns to the range between the minimum and maximum deactivation threshold and re mains in this range for the duration of the deactivation time P f intentional del...

Страница 83: ...o remain on the grid or not Protective settings take the upper hand over the capacity of immunity to interference 10 3 1 Dynamic grid support by way of immunity to interference Interference immunity a...

Страница 84: ...60 ms after the incid ent has occurred Responses to changes in the voltage during the incident or to the voltage recovery at the end of the incident take place with the same dynamic The formula for c...

Страница 85: ...and 4 up to the limit of continuous current Zero current under voltage threshold Zero current threshold over voltage 0 80 Unom 10 Unom 0 1 108 129 Unom 125 Unom 0 1 If one or more phase phase or phase...

Страница 86: ...g of residual current is limited to permit a defined proportion of active power components Minimum support time 1 000 15 000 ms 5 000 ms 10 If due to a voltage jump in accordance with formula 1 and th...

Страница 87: ...limitation If the ramp time WMaxLimPct_RvrtTms in the SunSpec model is specified as 0 s then the internal output gradient is used Otherwise the set value will be used Irrespective of the communicatio...

Страница 88: ...start up is usually only required for start up after a device has been switched off by grid protection The soft start up is implemented by an absolute power limitation that increases with a continuous...

Страница 89: ...anded grid behaves like a resonant circuit as a consequence frequency is proportional to reactive power balance and voltage is proportional to active power balance The active enhanced island detection...

Страница 90: ...tion outside of feed in operation renewed use of the Q on Demand function is only possible after proper feed in operation with sufficient DC supply The existing deactivated night shutdown also remains...

Страница 91: ...on troubleshooting and fault rectification Contact our Customer Service department Only perform the maintenance work that is de scribed here 2 Log each maintenance activity in the Service menu item S...

Страница 92: ...ny aggressive cleaning agents and ensure that no other components come into contact with fluids Cleaning completed if necessary remount the fans 1 2 mm 2 3x Fig 75 Cleaning the cooling fins from above...

Страница 93: ...h sides place it on the mounting clips and carefully press it in 2 Insert the fastening screws into the cover on both sides and tighten them _T20 2 Nm You may now start up the device See section 8 Pag...

Страница 94: ...2 Disconnect the DC side using the external DC isolator switch DANGER The DC cables are still live After shutdown wait 5 minutes before opening the device 11 6 Faults 11 6 1 Procedure DANGER Lethal v...

Страница 95: ...when the device goes into feed in mode after the start up period is complete the device s hardware is probably damaged Contact KACO Service to test the hardware E The device is displaying an impossibl...

Страница 96: ...es Fault LED red Status Explanation LED FS fault status Fault signal relay has been tripped To Feed in was ended due to a fault OS operating status The fault relay releases again Off The device feeds...

Страница 97: ...ior to beginning grid feed Should only be re garded as an error if one of the self test routines gets stuck If the device re mains in this status continuously des pite adequate DC voltage this indic a...

Страница 98: ...case The reactiva tion time is I Check PE cabling the cause is gener ally faulty cabling to earth Often occurs during rainfall in the case of faulty cabling Measure the insulation resist ance of the...

Страница 99: ...The voltage of the DC generator is too high The PV generator is configured incorrectly Check PV voltage using suitable meas uring equipment Are strings connec ted in series instead of in parallel E 41...

Страница 100: ...meters menu Check connection cabling E 49 Grid failure overfrequency Measured value for grid frequency is below the permitted limit This limit is country spe cific See action in the event of a fault 4...

Страница 101: ...ponse No in dication on display behaves in the same way as normal feed in mode status 4 therefore no flashing This is a require ment from the grid operator 64 Output current limitation Power limitatio...

Страница 102: ...therefore stops once the 5th fault is triggered within 24h If the fault tends to occur in the event of precipitation or high levels of hu midity this indic ates the presence of an insulation fault on...

Страница 103: ...f the DC link voltage is not reached this will be displayed If the device stops feeding in then there is a fault Other wise a highly inductive grid is responsible for this Poll the wiring on the AC si...

Страница 104: ...r Check the voltage measurement upstream of and between the relays the difference can be a maximum of 24 V Switch off the device entirely switch off AC DC for min 5 minutes if the fault occurs again t...

Страница 105: ...vel according to the specified parameters subject to the AC voltage This functionality may for example be requested by the grid operator If there is no request the function can be deactivated B 148 Ex...

Страница 106: ...181 183 Insulation error plus See description in the event of a fault 181 See action in the event of a fault 181 184 Protective shutdown over current L1 int See action in the event of a fault 181 185...

Страница 107: ...204 Protection shutdown grid voltage effective value L2 See description in the event of a fault 203 See action in the event of a fault 203 205 Protection shutdown grid voltage effective value L3 See d...

Страница 108: ...terface B 227 Protective shutdown current asymmetry Schutzabschaltung die bei hochohmigen Netzausf llen f r eine sichere Abschaltung des Ger tes sorgt NOTE Fault number not found If fault numbers are...

Страница 109: ...2 2 1 AC connection It has been ensured that there is no AC DC voltage present Remove the housing cover and put it aside 1 Detach cables L1 L2 L3 from the AC connection terminal W_17 2 Detach the PE l...

Страница 110: ...ched off and uninstalled 1 Remove the screw that prevents the device from being lifted off the mount 2 Use the lateral openings and lift the device off the mount Device removed Proceed with the packag...

Страница 111: ...g transport packaging are made from recyclable raw materials Unit Do not dispose of faulty devices or accessories together with household waste Ensure that the old devices and any accessories are disp...

Страница 112: ...the fault Consignment identification Delivery address Contact person with telephone number Information about the accessibility of the installation site You can find the following items and other info...

Страница 113: ...nt technical state at the time of printing Subject to technical changes No liability for printing errors Werner von Siemens Allee 1 74172 Neckarsulm Germany Tel 49 7132 896 0 info kaco newenergy de ww...

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